COMING FULL STARTING UP WINTER WARMTH CIRCLE A DREAM FROM FOREST
MAGAZINE OF PULP & PAPER // NO. 34 / 2-2016 MAGAZINE OF PULP & PAPER St. Croix Tissue // 06 Klabin S.A. // 10 Mjölby-Svartadalen Energy AB // 38
RED LIQUOR. GREEN POWER.
A "game changing investment" for Tembec provides long-term benefi ts at Temiscaming // 21 2 NO. 34 / 2-2016
10 38
Switch on GREEN POWER solutions from ANDRITZ
More and more companies are switch- ing on their GREEN POWER options. ANDRITZ offers a range of technolo- gies for producing solid biofuels and energy from waste by-products.
We have included several stories in this issue of SPECTRUM, highlighted with the GREEN POWER symbol, which showcase our customers’ successes 16 25 with renewable energy technologies.
CONTENTS
03 Management message 18 Healthy heart 36 SMART Simulation in design Paloma Hygienic Paper ANDRITZ AUTOMATION 04 News 21 Red liqour. Green power. 38 Winter warmth from the forest 06 Coming full circle Tembec Inc. Mjölby-Svartådalen Energi St. Croix Tissue 25 "Everything here is BIG" 42 Orders & Start-ups 10 Starting up a dream Interview with Fibria project directors Klabin S.A. 43 Did you know that? 29 Energy-effi cient fi ber treatment 16 Pumping up Puma TechTalk Klabin S.A. 32 It must be brilliant! Iggesund Paperboard
On the cover: Red liqour. Green power. (page 21)
SPECTRUM is published by: Editorial Director: General information and copyright: ANDRITZ AG Robert Puhr You will see the use of both “tonnes” and Stattegger Strasse 18 [email protected] “tons” in this publication: tonnes for metric 8045 Graz, Austria Editorial Board: units and tons for American units. SPEC- Phone: +43 (316) 6902 0 Bjørn Hansen, Minna Heinonen, Robert Puhr, Regina Puschnig, Dietmar Scherer, TRUM is published in three languages; Eng- [email protected] Andrea Schlagbauer, Ursula Suppanen, Manuela Wagner, Elisabeth Wolfond lish, Chinese and Japanese. Copyright© Editor-in-Chief: Contributing Writers: ANDRITZ AG 2016. All rights reserved. No Bjørn Hansen Robert Puhr, Mark Rushton, Gary Thomson part of this publication may be reproduced [email protected] Contributing Photographers & Providers: without permission of the publisher. Project Director: Scott Areman, Eric Howard, Hans Renzler, Jim Storm, Thomas Wedderwille, Otmar Manuela Wagner Winterleitner [email protected] Layout & Design: INTOUCH Werbeagentur & Internetagentur, Austria spectrum.andritz.com NO. 34 / 2-2016 3
ecades ago, a papermaker could produce a stronger sheet ware not only collects and analyzes mill data, but performs diagnos- OR a whiter sheet OR lower basis weight OR higher filler con- tics in real-time. It then notifies mill personnel about opportunities or Dtent OR lower energy usage OR more throughput. But, not all problems. Imagine your operators and maintenance people having this at the same time. information available not only in the control room, but also on their mobile devices (tablet or smartphone): What changed? The first quantum leap was the advent of computer control. This Simplified process layouts with real-time equipment status and brought with it the concept of optimization. (“We can monitor jet-to- performance (clear visual image of what is working well and problem wire, draws, weight, and moisture – so we can optimize for each.") equipment that needs attention).
We are now in the midst of the next quantum leap. Some call it “In- An equipment “EKG” (similar to an electrocardiogram in a doctor’s dustry 4.0,” others refer to it as the “Industrial Internet of Things (IIoT).” office) that not only shows the signal of the equipment’s “heartbeat,” Whatever the name, it brings the potential for optimization to an en- but also diagnoses the equipment’s health. tirely new level. Optimization relies on data (lots of it) and An OPP “toolbox” window speed: data to analyze trends for motor management, con- in terms of the bigger picture, trol loop assessment, valve and speed of response to OPTIMIZATION: monitoring, and an equipment get information to operators logbook. and maintenance at the mo- MOVING FROM “OR” TO “AND” ment they need it. No human A two-way Smart Glass – even your most dedicated application (wearable digital and talented – has the capac- computer) that sends live vid- ity to handle thousands of in- eo to an expert and, in return, puts and make thousands of receives maintenance and re- computations per second. pair info for the specific equip- ment being viewed. What makes the latest “quan- tum leap” possible is our ac- A predictive tool that mines Joachim Schönbeck, Member of the Humbert Köfler, Member of the cess to new data through Executive Board, Capital Systems. Executive Board, Service & Units. high-level data from all the the IIoT connection AND the mill’s computer systems and ability to deliver diagnostics predicts key process variables on-the-fly. Many machines now have the ability to monitor their health (production, quality, energy, etc.) 12 hours beforehand so that correc- and performance and report their status to other machines and higher- tive actions can be planned. level systems. In addition, the higher-level systems (what we used to call “process control computers”) are now linked to millwide business These tools are not “science fiction,” but are examples of the impact of databases, giving them access to sales, energy, productivity, mainte- IIoT and Industry 4.0. They are being used today. For example, we cur- nance, and quality trends. rently use Augmented Reality at two mills in South America. Video from the field (obtained through a Smart Glass worn by a mill maintenance We at ANDRITZ are taking these exciting new tools and developing person) appears on our equipment expert’s computer – allowing him/her them specifically for pulp and paper producers. We have written be- to guide the maintenance person through the steps necessary to trouble- fore about our service/solution called Optimization of Process Perfor- shoot and repair. In another application, the Smart Glass links the person mance (OPP), which melds high-powered analytical software (capable in the field with the DCS operator during a restart after a shutdown. of data-mining the thousands of signals in a mill’s databases) with the experience of very skilled people who know the process and equip- Our tools, in combination with the experience and knowledge of your ment. In its early form, OPP had a dedicated expert (either at the mill or best operators and maintenance people, will raise the performance of remotely) who would sift through the data trends and bring problems/ your mill. The ability to make real-time optimum decisions about grade opportunities to the mill’s attention. The efficiency improvements and mix AND quality AND productivity AND energy AND raw material costs costs savings in this approach were well documented. AND chemical consumption AND equipment health is growing rapidly. We look forward to working with you to continue this growth. The latest innovation in OPP brings us closer to true optimization. In many cases, the dedicated expert can be eliminated. Powerful soft- Sincerely,
Joachim Schönbeck Humbert Köfler NEWS4 NO. 34 / 2-2016 New generation bark press makes its debut
The patent-pending ANDRITZ HQ-Press delivers bark with approxi- drum with two-phase pressing to achieve the higher dryness. While mately 5%-units higher dry solids content than any competitive unit. conventional presses typically achieve an annual average of 40% dry This can increase the net green energy value of the bark up solids, the HQ-Press is able to deliver an an- to 15%. nual average of 45% dry solids in normal operation. Advanced Unlike competitive units that have enclosed controls on the unit maximize structures, the HQ-Press has an open, the output under a variety of op- simple design. The components are easily erating conditions. The HQ-Press accessible for maintenance. As a side is a robust, reliable solution for bark benefit, the open design helps with handling in any woodyard or housekeeping activities, which biomass handling operation. reduces odors and mold spores in the operating environment. Find out more about the HQ-Press The design of the HQ-Press www.andritz.com/ features a self-orienting hq-press
Update from Äänekoski: bleaching towers arrive on-site
In what has been called one of the largest days to complete (mostly during the nights) road transports ever in Finland, ANDRITZ and involved lifting of telephone and electric bleaching tower segments made their way lines, removal of portals at roundabouts, and by truck to this bio-product mill under con- some reinforcement of certain roads. struction in central Finland. While there will be about 150 special transports from ANDRITZ ANDRITZ is supplying the wood processing in support of this project, this one was very plant, fiberline, evaporation plant, and recaus- impressive. ticizing plant for the new 1.3 million tonne bio-product mill that Metsä Fibre is building The sections (the largest being 9 m wide x adjacent to the existing Äänekoski mill. 10 m high x 22 m long) were transported by trucks from Pietarsaari to Äänekoski. Total For more info please contact: weight of the two largest tower segments was [email protected] 193,000 kg. Total transport time took four NO. 34 / 2-2016 SPECTRUM News 5
UniFeed upgrade for wash presses
Older wash presses often have signifi cant limitations: frequent plug- ging, limited throughput, and limited feed consistency.
ANDRITZ is now offering an easy-to-install upgrade – UniFeed – which helps overcome these limitations. UniFeed creates a homogeneous pulp web over the roll’s entire screen area. Washing effi ciency and throughput are improved since the wash press can now operate at a higher feed consistency. With plugging problems virtually eliminated, availability of the wash press is increased. With a lower pressure drop in the feeder, less energy is consumed. Plus, it is safer to operate since no manual cleaning is required under the unit.
Depending upon the brand and model of the existing wash press, on-site work to perform the upgrade can be accomplished in as little as four days.
For more info please contact: [email protected]
Not pretty, but an important raw material
Pulper rags – that beautiful string of “waste” that is formed in the vortex during recycled fi ber pulping – can be a very valuable raw material source. For the longest time, this waste stream (which contains a high portion of steel baling wire) was cut into manageable pieces and sent to landfi ll. However, this steel has value when it is sold to a recycler.
Up until now, it was diffi cult to fi nd the right shredding technology to handle this task. ANDRITZ has developed a two-stage process for turning diffi cult-to-handle pulper rags into a revenue stream. In the fi rst stage, the rags are fed to a coarse shredder called the ANDRITZ UC Universal Rotary Shear. For stage two, an ANDRITZ UG Universal Granulator is used to cut the shredded rags into the proper size and loosen up the material so the wire fractions can be easily removed.
Normally, an overband magnet is used to remove the steel wire frac- tion, which can be sold. The residual fraction (mostly plastics and some cellulose) has a high calorifi c value and can be used as a fuel Find out more about ANDRITZ solutions for pulper rags: source for the mill. andritz.com/pulper-rags 6 NO. 34 / 2-2016
Coming full CIRCLE
Two decades ago, the Woodland mill in Maine was a vibrant pulp and paper complex. Suffering the fate of many commodity pulp and fi ne paper mills, Woodland was near extinction in 2010 when a company with a vision bought the assets, injected USD 180 million (EUR 155 million), and changed the course to value-added tissue production.
St. Croix Tissue is among the newest pro- “Without question, the addition of tissue mak- down. The future of this facility as a producer of ducers of premium tissue parent rolls in North ing capabilities saved this pulp mill,” says commodity pulp was simply not sustainable.” America. The machine hall is built next to an Arvind K. Agarwal, CEO of International Grand existing hardwood pulp mill (Woodland Pulp). Investment Corp. (IGIC), the parent compa- The rebirth of the mill has special meaning to Mirror-image ANDRITZ PrimeLine tissue ma- ny of Woodland Pulp, St. Croix Tissue, and Marty Richard, Tissue Manager. Richard was chines, which started up in 2016, are quickly Cascade Pacifi c Pulp mill in Halsey, Oregon. raised in the local community and worked at ramping up to a combined design production “Just prior to our buying Woodland in 2010, the the mill for 16 years. “We saw some tough of 126,000 t/a. owner (Domtar) put the mill into indefi nite shut- times and it looked like the end was near,” Richard says. “In the late 1980s, there were 1,200 people working in the pulp, paper, and oriented strand board (OSB) plants around here. Before IGIC came in, there were about 320 people left in the pulp mill. To come full circle where we are investing and hiring – for a mill that has a bright future – is really rewarding to be part of.”
St. Croix’s Marco L’ I t a l i e n , V i c e Setting the stage President (left) with “When we acquired Woodland in 2010, we Marty Richard, Tissue Manager. already had the idea to maximize our return by NO. 34 / 2-2016 St. Croix Tissue 7
adding tissue making capacity,” says Agarwal. ANDRITZ was able to fulfi ll all the requirements nuisance breaks since we have eliminated “My job was to turn this facility around by con- of our spec.” the steambox and simplified the machine.” verting it from a commodity producer to a value-added facility.” Of importance was a specification for a Another consideration was machine width. steel Yankee instead of cast iron, because “To meet the needs of one of our key custom- Agarwal and his team went to work imme- of the heat transfer advantages and safety ers,” Richard says, “we needed a machine diately. “First thing,” Agarwal says, “was to factors. St. Croix specified 18-foot di- that would give us roll widths from the stan- reduce our dependence on oil by bringing ameter Yankees instead of the standard dard 102 inches (2,591 mm) up to 112 inches natural gas to the mill. Local distribution 16-foot ones. “The larger Yankees were a (2,845 mm). Not too many tissue manufactur- companies said it would take several years good choice,” L’Italien says. “We don’t have ers have this capability on-machine.” to permit and build a pipeline. We did it in 10 months with an investment of USD 17 million. That was a positive indicator to the employees and community that we meant business.” The future of “There were also investments to improve the this facility as reliability and throughput of the kraft mill,” a commodity pulp says Marco L’Italien, Vice President. These investments set the stage for the announce- mill was simply not ment in 2013 that a new tissue mill would sustainable.” be built.
Arvind K. Agarwal Proven supplier CEO, International Grand Investment According to Tom Dorsch, Project Leader for Corp. St. Croix, “We went through a very detailed process to develop the specs for this mill, and 8 NO. 34 / 2-2016
“We have come to appreciate ANDRITZ’s On the equipment side, ANDRITZ delivered “even though we had fewer resources since contribution not only for their up-front engi- the first machine in May and the second one TM1 was in full operation by then. We had a neering, but also for their understanding of in August 2015. “We began commissioning good start-up in July 2016.” the entire process,” Agarwal says. “They have TM1 in January 2016,” says John Schamell, been an excellent partner the entire time – from ANDRITZ’s North American Vice President for “In our first full month of operation with both the initial design to optimization of the mill. They tissue and drying. “Even though construction machines, we reached 70% of saleable have also kept in the forefront of technology, was proceeding around us, we checked out design capacity for this mill,” Dorsch says. ahead of their competitors.” the machine section by section. It was a little "That's a very fast ramp-up." hectic and the operators were brand new. But, Building the vision we got stock on the wire in early March.” When asked about the working relation- The contract with ANDRITZ was signed in ship with ANDRITZ, Dorsch comments, January 2014. Groundbreaking for the new The second machine was commissioned and “Whenever there were issues, ANDRITZ took mill occurred in October 2014. “We had one of started up with a more traditional approach ownership. Any problem got fixed and got Maine’s harshest winters,” Dorsch recalls. “At and pace. “It started up well,” says Schamell, fixed well. They were very open and trans- this time, we were doing the deep foundation work. There were challenges to be sure, but all of the suppliers, including ANDRITZ, stepped up to help us recover schedule.”
For the Baileyville area (population 1,500), this was a massive construction project. “Logistics was one of our biggest challenges given our remote location,” Dorsch says. “It is 35 miles to a deep water port, 90 miles to the closest St. Croix specified a large Steel Yankee airport, and highway access is by two-lane (18-foot diameter) roads. We had over one million construction for both machines. TM1 started up in hours involving 525 people on-site at our peak March and TM2 in in the middle of winter.” July 2016. NO. 34 / 2-2016 St. Croix Tissue 9
Mirror-image PrimeLine tissue machines. Design speed is 2,000 m/min. Width 5.6 m. Capacity 126,000 t/a combined.
Tom Dorsch, St. Croix Project Leader (left) with John Schamell, ANDRITZ’s Vice President North America for Operators in the control room for TM1 and TM2. tissue and drying, on TM2.
parent. They were always sensitive to tim- our group,” Dorsch says. “This is the third Excellent runability – ing, costs, and the impact on our operations. machine-pair start-up I have worked on excellent smoothness They are an excellent partner that way.” and I can say that this project had more “Every converter, who has run our tissue, likes vendor support than I have typically seen. it,” L’Italien says. “One converter was able to Multinational machine But, it was essential here given that our raise speeds by 70% due to the runnability of About 85% of the machine components workforce was green with very little tissue our product.” were manufactured at the ANDRITZ facility in experience.” Foshan, China. The Steel Yankees were fabri- St. Croix considered investing in struc- cated in ANDRITZ’s state-of-the-art workshop St. Croix partnered with the local commu- tured tissue, but decided to go with the in Hungary. Headbox, press rolls, and hydraulic nity college to design a training program CrescentFormer. “Even though our tissue systems came from Europe and the air sys- so potential job candidates could learn is not structured, it is of very high quality,” tems came from Canada. about tissue making. Completing the pro- Richard says. “In some cases, it has allowed gram did not guarantee a job, only gave us to get a foot in the door in traditional “Like many North Americans, I wondered the opportunity for an interview. “Then in structured markets. The formation on the what the quality of the components manu- August 2015, we hired the initial team of CrescentFormer is just so good that we can factured in China would be,” Richard says. 58 employees,” Richard says. “The com- compete well in the softness for the higher “I went to the ANDRITZ workshop in Foshan munity college again partnered with us for end bath tissues.” to inspect the first machine. It was clear that a four-month training program. Much of quality was the first thing on the minds of the this training was conducted by suppliers, “Before we started up, I was concerned about people – we didn’t even have to ask the ques- including ANDRITZ.” physical quality of the reels, since we would be tion before management was explaining their making 88-inch (2,235 mm) diameter rolls,” QA/QC processes. It was impressive. After Part of the funding for this project comes L’Italien says. My concerns were unfounded. delivery, we could see that the workmanship through a New Market tax credit program. These machines make nice flat rolls with excel- was really excellent.” A requirement for that credit is that St. Croix lent profiles. Whatever ANDRITZ is doing with hire 60% of its new employees from a low- its reel building technology certainly is working.” Local training partnership income bracket and maintain that ratio for “ANDRITZ committed a very good team to seven years. “This has a huge benefit for the CONTACT David Hathaway this project, and they integrated well with community,” L’Italien says. [email protected] 10 NO. 34 / 2-2016 Starting up a DREAM NO. 34 / 2-2016 Klabin S.A. 11
The opportunity to work on a greenfield mill project is the dream of many people in our industry. The people who helped create the 1.5 million t/a Puma Mill exactly on time certainly lived the dream. This includes ANDRITZ, which was recognized as being the best performing supplier in the project.
It seems that all the stars were aligned pre-feasibility studies) was carved out of for the birth of the Puma Unidade (mill) Klabin’s 270,000 ha of forests in Paraná in Ortigueira. The speed with which the state. “There was nothing but trees and project progressed from construction to hills here when we arrived,” says João completion (24 months) was remarkable. Braga, General Manager for the Puma The virtually error-free start-up and ramp- Project. “The amount of earth we had to up of the mill not only pleased Klabin’s move to level out this site makes this the shareholders, but gained the respect of largest earthmoving project that we know the international pulping community. of in the industry.”
At the mill’s inauguration in June, large Transportation is a major issue for any banners gave a hint of Klabin’s secret for mill. The existing roads to the site were success: not good enough, so Klabin built a new road to improve access, a 22 km long rail- Dream + Execute way to connect the mill to the existing net- Klabin’s formula for achieving work, and another road with a bridge over extraordinary results the Tibagi River to accommodate logging trucks without having to put traffic on pub- The Puma Mill (named for mountain lions lic highways. As part of the project, Klabin that live in Klabin's preserved native forests also built 100 km of power transmission and were spotted in the area during the lines.
The dream has been achieved and it will help Klabin keep growing.”
João Braga Project General Manager, Klabin 12 NO. 34 / 2-2016
Overview of the ANDRITZ woodyard with one of the two 360° stacker reclaimers in the foreground and four chipping lines in the background.
(L to R): Klabin’s João Braga, General Project Manager; Edemilson Pagano, Project Manager for the fi berline; and Rodrigo Santos, Project Coordinator for the fi berline in front of the DD Washers.
“Considering that we have four debarking “Even with this, we started production exactly Razzolini says. “Annual production capac- lines, two fiberlines, a large energy plant, as planned two years ago,” says Braga. “Our ity will be 1.5 million tonnes (1.1 million and an extra converting machine for fluff target was to feed chips to the hardwood di- tonnes of hardwood and 400,000 tonnes pulp, we estimate that there is about 40% gester on March 1st and we did it.” of softwood). A sizable portion of the soft- more equipment in this mill than a normal wood will be processed as fluff pulp.” single-line eucalyptus mill,” says Francisco Fiber advantage Razzolini, Director of Industrial Projects “We use short and long fibers from the Brazil mostly imports its fluff pulp to- and Technology, two ANDRITZ fiberlines in ways that give day. Interestingly, Klabin produced small us both technical and cost advantages,” amounts of fluff back in the 1990s.
From the beginning, ANDRITZ put excellent people on this project and managed all aspects of their work very well.”
Francisco Razzolini Director of Industrial Projects and Technology Klabin NO. 34 / 2-2016 Klabin S.A. 13
In the white liquor plant, there are two kilns (capacity 650 t/d each). The recausticizing plant is designed to produce 16,000 m3/d.
“Resuming production will enable Brazilian commercial sale of our power (50 MW) to Best available customers to source fluff pulp locally,” the national grid in July,” Razzolini says. “We are using the best available world- Razzolini says. “Our plan is to increase this to 150 MW by class technologies to maximize yield the end of the year.” and minimize emissions and effluents,” A shift in strategy Razzolini says. “The ANDRITZ DownFlow The Puma Mill marks a change in Klabin’s Local labor – local employees Lo-Solids cooking process gives good business strategy, which has been focused “In order to be successful, one of the things flexibility and excellent quality pulp; their on packaging papers and corrugated we had to do well was to manage the huge DD washers are well-proven in reducing boxes. "We move from being a 1.8 mil- amount of people working on-site,” says chemical consumption.” lion t/a paper and boxboard supplier to a Razzolini. “At the most hectic time, there 3.5 million t/a company producing paper, were 12,000 people here. We were also For wood processing, Klabin also selected board, fiber, and green energy.” Total in- building roads, transmission lines, rail- ANDRITZ. The Puma Mill will process about vestment in the project was BRL 8.5 billion ways, etc. nearby which added another six million tonnes of wood each year with (EUR 2.33 billion), the biggest investment 3,000 people.” four large chipping lines from ANDRITZ. in the company’s history. The average distance from forest to mill Since many of the new employees are lo- gate is only 72 km, which ensures a low to- Another Brazilian pulp producer, Fibria, will cal and did not have specific pulping ex- tal fiber cost. “These chipping lines are the be the exclusive sales partner for most of perience, Klabin elected to use the IDEAS largest equipment that ANDRITZ makes,” Klabin’s hardwood pulp (900,000 t/a) in dynamic simulator from ANDRITZ. IDEAS Razzolini says. “We use three for eucalyp- countries outside South America. models the operation of the fiberlines, tus and one for pine.” bleach plants, white liquor plant, evapo- Energy exporter ration plant, recovery boiler, and power On the white liquor side, Klabin opted for The new mill has the two largest turbine- boiler (some of this equipment is outside two smaller ANDRITZ kilns rather than one generators ever built for the pulp and paper ANDRITZ’s scope of supply) to check out large one. “Bringing in make-up lime to this industry. The units have generation capac- the DCS loops and then train employees mill would be difficult,” Razzolini says, “so ity of 270 MW. Biomass accounts for about in a “virtual” environment before the mill we wanted to have redundancy in this area 20% of the energy generation. “We started started up. to increase our operational flexibility.” 14 NO. 34 / 2-2016
Percio Pereira, ANDRITZ Project Manager for the white liquor plant, standing in front of the two lime kilns.
Best supplier “In addition to being on time, the start-up was smooth,” Razzolini re- ports. “The ramp-up is better than we planned, and the safety record is better than any project that Klabin has done in the past. The commit- ment of all our suppliers was very high – all were working to the same goals with us.
“We consider ANDRITZ to be the best overall supplier on this proj- ect,” Razzolini says. “From the be- ginning, they put excellent people on this project and managed all aspects of their work very well – both here and abroad. There were very strong and positive relationships between ANDRITZ and our project managers. Their support in training our people and the quality of their team during Close-up of the 360° stacker reclaimer at start-up was excellent. This project ANDRITZ woodyard and also had high visibility and support two ANDRITZ fiberlines in the backround. from the top managers at ANDRITZ.”
Braga shares a similar view. “ANDRITZ has a very good project organization,” he says. “They man- NO. 34 / 2-2016 Klabin S.A. 15
ANDRITZ delivered two fiberlines for the mill: a 1.1 million t/a hardwood line and a 400,000 t/a softwood line. Much of the softwood will be used for the production of fluff pulp.
aged the work of three different civil con- ing was completed and we could do the monitoring kept us on schedule and saved struction companies and three different soil survey and civil engineering. We put us considerably in change orders with our mechanical erection companies. It meant more labor effort in and all the lost time suppliers.” more coordination work for their team, but was made up.” it reduced project risks and maintained Dreaming … and then competitiveness. I think that was smart.” Engineering coordination executing “We were under a tight time schedule “For me person- Complete cooperation erecting two fiberlines in the same time that ally, this project has Braga and his team had weekly meetings a single line would normally be built,” says been a dream come with key suppliers. “If we found any devia- Andre Ehlke, ANDRITZ Project Engineering true,” Braga says. tion from the plan, we acted immediately,” Coordinator for the fiberlines. “We had to “It was a wonder- he says. “We all worked together. When a get the engineering done on time, and it ful professional supplier had a problem, we all had a prob- had to be right to avoid rework in the field. challenge for me lem, and we all worked to recover.” So, we set up our project organization a and a great op- little differently and created the role of proj- portunity to be A good example of the joint cooperation, ect engineering coordinator.” part of the larg- according to Braga, was when Klabin est investment in faced some earthmoving delays in the A system was developed to have better my company’s his- white liquor plant area. ANDRITZ could information about, and control of, basic tory. The dream has not start its soil survey work until the area engineering. The project engineering co- been achieved and was ready. Valuable time was being lost. ordinators monitored the amount of data it will help Klabin keep “ANDRITZ immediately went to work with that was being entered into the software growing.” a recovery plan,” Braga says. for developing flowsheets and other docu- ments. “This gave us a measure of engi- “We discussed with Klabin and came neering effort, both internally and with our up with a solution,” says Percio Pereira, external engineering companies,” says ANDRITZ Project Manager for the white li- Ehlke. “It also showed how much work quor plant. “We decided to move the entire remained to be done, so we could focus CONTACT Rafael Sirtoli plant 21 m to a part where the earthmov- on areas that needed attention. This close [email protected] 16 NO. 34 / 2-2016
About 425 process pumps and specialized pumps – virtually The decision to utilize ANDRITZ pumps re- sulted in a frame agreement through which all the pumps at Klabin’s Puma Mill – were supplied by the EPC contractors at the Puma Mill could ANDRITZ. specify ANDRITZ pumping systems for its various process areas. In total, there were nine EPC groups plus Klabin with specifi c The start-up and ramp-up of Klabin’s Puma the largest and most advanced mills in the needs, delivery times, etc., coordinated by Mill in Ortigueira has special signifi cance for world, the order for 425 centrifugal pumps – ANDRITZ HYDRO. the Pumps Division of ANDRITZ HYDRO, containing 19 medium-consistency pumps one of ANDRITZ’s main business areas. – was one of the largest orders the Division In addition to the logistics of order handling, Not only are the pumps installed in one of has received from the pulping industry. ANDRITZ specialists were in demand for pump sizing, drawings, documents, and other engineering tasks. These low-mainte- nance pumps have Most of the pumps were supplied through been optimized for use in the pulp and ANDRITZ HYDRO’s Brazilian subsidiary. paper industry, where The pumps were manufactured at ANDRITZ they operate with an effi ciency of over 90% factories in Austria, China, and Germany. with low pulsation. ANDRITZ pumps were installed from the raw water intake system, through the mill, and to the wastewater treatment process. Five two-stage vertical line shaft pumps were installed on a fl oating barge (fi rst time in the pulping industry), combined with fi ve booster split-case pumps (750 kW motor NO. 34 / 2-2016 ANDRITZ HYDRO 17
These single-stage centrifugal pumps are used as process pumps in various areas of the pulp mill. With efficiency of up to 90% and the ability to transport pulp suspensions of up to 6% b.d., these pumps are true all-rounders.
and flywheels) to transport water to the mill from the nearby Tibagi River.
A large portion (99) of the ANDRITZ pumps are installed in the fiberline. Of these, the majority are single-stage centrifugal pumps of various designs with efficiencies up to
90% capable of transporting suspensions The ANDRITZ up to 6% consistency. Two high-pressure MC-pump was de- veloped specially to pumps are also installed in this area. The convey viscous me- medium-consistency pumps move pulp dia. It can transport pulp suspensions of suspensions up to 16% consistency with- up 16% b.d. without out difficulty. any difficulty. They reach an efficiency of over 70%. In addition, dozens of process pumps from ANDRITZ were installed in the boilers, evaporation plant, drying plant, and chemi- production exactly as planned when the Such a huge project demanded a lot cal preparation plant delivered by other EPC original contracts were signed. of interaction between HPU locations. suppliers. Six split case pumps, weighing Communication was a key to success. The nine tons each and driven by 1,000 kW In order to be able to respond quickly to lessons learned have also prepared the motors, were installed in the cooling tower maintenance and servicing of the pumps, team for similar projects in the future. system. Klabin set up a store in the mill with ANDRITZ recommended spare parts and wear parts. Installation, commissioning, and start-up ANDRITZ is also collaborating with Klabin to were supervised by field technicians from develop an innovative “shop-in-company” CONTACT Roberto Barce Brazil and Austria. The Puma Mill started concept at the Puma Mill. [email protected] 18 NO. 34 / 2-2016 HEALTHY HEART Long, productive life
It is said that the Yankee is the heart of a tissue machine. To keep its machine’s heart healthy, Slovenian tissue producer Paloma Hygienic Paper relies on Yankee service from ANDRITZ. There are numerous advantages for Paloma to these on-site services.
Paloma Hygienic Paper is headquartered in that technology plays in developing her know the softness and quality of the end Sladki Vrh, Slovenia, close to the Austrian company’s varied products. “Most con- product in their hands. We in the business border. Paloma has more than 140 years’ sumers do not think of high-technology think about technology at every step – from experience in the production and sale of when they think of their everyday facial or the preparation of the raw material, to the high-quality hygiene papers and today is a bath tissues,” Bedenik says. “They only production steps on the tissue machine.” leading supplier in the Adriatic region and Central Europe. Annual production is more than 70,000 tonnes in the form of kitchen The heart of the ma- rolls, paper handkerchiefs, paper napkins, medical towels, and different kinds of toi- chine – the Yankee – let paper. In addition to its own brands, is of special importance in en- Paloma develops and produces private suring quality and maintaining label products for leading European retail chains. effi cient production.”
Nataša Iršič Bedenik is Head of R&D and Nataša Iršič Bedenik Head of R&D and Quality Management Quality Management at Paloma. As such, Paloma Hygienic Paper she has a deep understanding of the role NO. 34 / 2-2016 Paloma Hygienic Paper 19
TM3 at Paloma, where ANDRITZ per- formed on-site grinding/coating services.
unfortunately led to a number of Yankee ANDRITZ is an expert in Yankee dryers. Its ex- failures over the years. pertise starts with the design of new Yankees, through the manufacturing of the cylinders in In addition, producers are seeking to make a specialized workshop with extremely high greater quantities of tissue at higher quality, quality assurance standards, and extends to increasing the demands on the Yankee. The cover on-site services at tissue mills around Thermal coating applied to the Yankee on-site with largest Yankees in tissue production are now the world. PrimeCoat Stratos. 22 ft (6.7 m) in diameter with machine speeds in excess of 7,000 ft/min (2,100 m/min). According to Wolfgang Herbst, Sales Engineer for Paper Machine Service and Because of its importance, the Yankee re- Spare Parts, ANDRITZ services include Bedenik knows that key quality and soft- quires monitoring and regular maintenance. on-site checks, measurements, and per- ness parameters are established in the fi rst “We became aware of ANDRITZ’s compre- formance tests. “Sometimes, Yankee prob- few production steps. From her perspective, hensive Yankee service,” Bedenik says. “They lems are not due to any fault of the Yankee, “The heart of the machine – the Yankee – is view the Yankee as part of the complete pro- but because of the failure of some system of special importance in ensuring quality and duction process instead of as a stand-alone or component supporting the Yankee,” he maintaining effi cient production.” unit, and we share that view. Their service, says. “That is why we take a holistic view of which combines specifi c knowledge about the Yankee being part of the entire produc- Indeed, the Yankee – that massive rotating the Yankee in the context of the entire pro- tion line. A program to monitor valves, bear- pressure vessel – serves a vital transport duction line, is what led us to select ANDRITZ ings, lubrication, and interlocks is essential function (supporting the tissue web through as our strategic service partner.” for long and safe operation of the Yankee.” the drying process with no open draws) and is the component on which most of the water in the tissue web is evaporated while adding crepe and structure to the tissue sheet as it is From initial calculations doctored off the Yankee. to grinding/coating to Heart-healthy maintenance optimization, our services Just like the human heart, the many pro- substantially extend the useful cess variables and operations taking place can put the Yankee under considerable life of the Yankee.” stress. Steam pressure, rotational forces, temperature differentials, and line loads are Wolfgang Herbst Sales Engineer for Paper Machine Service all at work on the Yankee. This combination and Spare Parts, ANDRITZ AG of mechanical and thermal stresses has 20 NO. 34 / 2-2016
One of the measurements that ANDRITZ spe- competitive advantage for producers like competition in that they offer consultation cialists perform is an on-the-run (OTR) profile Paloma. before, during, and after the execution of the measurement to monitor the surface wear of work. Their pricing is very competitive. Their the Yankee at production speeds. “Our mea- Throughout a long, productive life speed of response to our needs or questions surements and tests indicate the proper time As the person responsible on-site at Paloma, is excellent. In our case, since we are close to grind the Yankee to minimize material re- Herbst knows the challenges of modern to their headquarters, collaboration is easy.” moval,” Herbst says. “Grinding, coating, and Yankee service well. “Each mill and each polishing are all activities that we perform on- machine is unique.” he says. “We offer much The work with ANDRITZ represents site to shorten the downtime.” more than a conventional service, which Paloma’s first strategic partner for mainte- means we focus on listening carefully and nance and service. “This is not something An added benefit of the OTR profile measure- responding to unique customer needs. We so traditional in our country,” Bedenik says. ment, Herbst explains, is that it "not only im- must be near the customer, ready to act. “The key for us lies in ANDRITZ’s expertise proves the drying process, but also can help We define our actions together as partners. in specialization. Our core competence is in resolving MD and CD issues related to wear Since needs are different, sometimes our ser- the development and production of tissue. patterns.” vices are highly customized. Whether for a It is not in the maintenance and service of new installation or a rebuild, our services ac- tissue machines. Their renovation of one of Starting with an audit company the customer throughout the long our important tissue machines showed their ANDRITZ was first brought in to audit the productive life of their Yankee.” depth of expertise. It also showed our ability performance of one of the tissue machines to manage a project with international team at the Sladki Vrh mill prior to a rebuild. The on- ANDRITZ Yankee service is for Yankee cyl- members and foreign experts. The project site grinding and coating of the cast Yankee inders delivered by any OEM. Services are was a complete success." for TM3 in 2016 met with Paloma’s complete available for all types of Yankees, Herbst satisfaction. This was the beginning of a close notes, for tissue or paper machines, MG pa- Paloma is confident it has found a reliable service partnership. A follow-on order for ser- per or tobacco, steel or cast iron Yankees, old service partner in ANDRITZ. “They will work vicing TM5’s cast Yankee was placed shortly or new. ANDRITZ offers solutions for operat- with us well into the future to optimize and afterwards. ing units or anticipated upgrades or replace- continuously improve our production stages, ments, and to solve specific issues related to which will improve the quality of our products,” ANDRITZ’s Yankee service focuses on safety, capacity, or quality. Bedenik says. adding value with the Yankee. A well-main- tained Yankee improves runnability and ef- “We really appreciate the competence of ficient production. The improvements in ANDRITZ and their willingness to trans- throughput, machine efficiency, and reduc- fer their knowledge to our people,” says CONTACT Wolfgang Herbst tions in downtime can trigger a remarkable Bedenik. “ANDRITZ stands apart from its [email protected]
ANDRITZ Yankee Service
Mechanical on-site services grinding, coating, leakage repairs, nip calibration, doctor blade adjustment, etc.
Consultation drying system, heat recovery, energy savings, runnability, etc.
Troubleshooting surface inspec- tion, steam and condensate, auto- mation, dewatering, chemicals, etc.
Inspections and measurements pressure testing, OTR, finite element analysis, acoustic measurement for crack detection, etc.
On-side machine check of Yankee shell thickness. 21 22 NO. 34 / 2-2016
The slogan for the Canadian forest products company Tembec is “Rooted in tomorrow.” This is an apt description of how a strong sense of history is blended with a forward-thinking strategy to find success in difficult markets.
To understand Tembec’s drive for success, (L to R): Michel Monet, Tembec; travel back in time to 1973 in Temiscaming, Paolo Dottori, Québec, a town whose livelihood depended on Tembec; Bernd Zuschin, ANDRITZ; the pulp mill that was shut down as being un- and Paul Cousineau, profitable in 1972. The mill’s rebirth was made Tembec, in front of the new SulfitePower possible by four individuals who teamed up boiler. with former employees of the mill, the residents of Temiscaming, and government authorities to purchase the shuttered mill. Against an invest- pulp mill, and a specialty cellulose mill here, boiler burns “red liquor,” which is a co-product ment of CAD 2.4 million (EUR 1.6 million), the with many swings in production,” he says. of the ammonia-based sulfite manufacturing company’s first-year after tax income was CAD “We needed an extremely robust boiler to process at the mill. 9.3 million (EUR 6.3 million). A Canadian suc- replace our old units that could handle our cess story was launched. variability of liquor swings. We also needed The main drivers, according to Paul certain fuel capabilities. The boiler had to Cousineau, Corporate Manager of Major The Tembec strategy has been to carve out be oversized by a certain factor. We wanted Projects (who stepped in to become a niche for the sulfite mill: tailor-made spe- dual scrubbing capabilities (ammonia and/or Tembec’s Project Manager after the original cialty dissolving pulps (ethers, acetates, ni- caustic). Plus, we needed a flexible condens- project manager experienced health prob- trocellulose, and microcrystalline cellulose), ing turbine design to handle outages and lems) were the age of existing boilers and the chemicals (lignosulfonates), and coated shutdowns in a variety of ways.” desire to reduce SO2 emissions considerably bleached board. “This mill has been here – plus the ability to create a steady stream for 100 years,” says Paolo Dottori, Vice Green electricity project of revenue from the power agreement with President of Environment, Engineering, and Tembec’s new CAD 273 million green elec- Hydro-Québec. Procurement. “The batch sulfite process tricity facility at Temiscaming is now produc- gives us higher pulp quality and the flexibility ing steam for mill processes and generating Efficiencies of the new ANDRITZ boiler improve to produce to buyer specifications.” power that it is delivering to the Provincial manufacturing productivity and reduce costs. utility, Hydro-Québec, through a 25-year sup- Once fully optimized, the new scrubber and As Dottori explains, Temiscaming is actually ply contract. The centerpiece is an ANDRITZ environmental control equipment will reduce a very complicated site from an energy per- SulfitePower boiler and electrical turbine with the mill’s SO2 emissions by 70%, which will be spective. “We have a board mill, a high-yield a generating capacity of just over 60 MW. The much appreciated by the local community.
Tembec’s new CAD 273 million (EUR 185 million) green electricity facility at Temiscaming is now producing steam for mill processes and also generating power that is delivered via a 25-year supply contract with the Provincial utility, Hydro-Québec. The centerpiece is an ANDRITZ SulfitePower boiler and electrical turbine with a generating capacity of over 60 MW. NO. 34 / 2-2016 Tembec Inc. 23
Best available technology ANDRITZ was selected to provide the engi- neering, the boiler itself, erection supervision (civil construction and erection were handled by Tembec), and commissioning services at Temiscaming.
“Sulfite mills are few and far between in Christoph Gruber, Canada,” Cousineau says. “The last recov- Commissioning Manager from ery boilers in North America for sulfite mills ANDRITZ (stand- were installed in the late 1970s. ANDRITZ has ing), with Trevor Turner, Head Boiler done considerable work since then by install- Operator, in the ing sulfite boilers and chemical recovery units control room. around the world. ANDRITZ has strongly pro- moted its design to the point that we believe it is the best available technology.” “We were looking for a highly flexible boiler to temperatures. They had reached the end of deal with the steam consumption swings at their useful life. Fouling was one of the biggest ANDRITZ is unique in that it offers all three this site and not have our utilities constrain our issues. This led to corrosion issues and made types of recovery boilers: black liquor (kraft), pulp production processes,” Dottori explains. maintenance more intensive.” red liquor (sulfite), and sodium liquor (for “ANDRITZ’s track record convinced us that example, sodium-containing effluents from they were the best supplier for this project. Tembec began talks with then Austrian Energy the BCTMP process). “Our first sulfite boil- We were especially impressed with their ca- & Environment (now ANDRITZ) in 2010 and ers were installed in the 1950s,” explains pabilities in handling different and difficult fuels sent out tenders the following year. “We be- Bernd Zuschin, ANDRITZ Project Manager, – even municipal solid waste, refuse-derived gan to talk in detail in 2011, and provided “so we have a long history and deep expe- fuels, and various cooking liquors. We have some budget estimates and calculations,” rience. We have continued to develop this two of their units at our sister mill in Tartas, says Zuschin. “We signed the contract with technology and this is certainly recognized France, which gave us a good reference.” Tembec in March 2012.” by our customers. For example, this is the first ammonium sulfite boiler we have ever “Liquor incinerators” ANDRITZ delivered all the boiler components built. Our deliveries up to this point have The new boiler replaced three operating boil- to the site by mid-2013. “This was a relatively been for magnesium-based sulfite process- ers and one boiler that had been shut down. fast-track for delivery, especially considering es. We also delivered the world's largest As Cousineau explains, “Our three old re- the sea transports from Europe to Canada, sulfite boiler and chemical recovery unit to covery boilers were what I like to call ‘liquor but we made all of the milestones,” says Sappi Saiccor in South Africa, started up incinerators’ since they were converted coal- Christoph Gruber, ANDRITZ Commissioning in 2008." fired boilers operating at low pressures and Manager.The boiler was started up early 2015. 24 NO. 34 / 2-2016
The ANDRITZ boiler has capacity to burn 78.5 t of wet liquor at 50% dry solids each hour, equating to Inside the boiler: liquor being sprayed into the furnace, atom- 942 tds/d producing 222 t/h of high-pressure steam. ized by steam.
Simplified operations and maintenance “We have room for expansion in our pulping “The entire steam plant team was involved Life for Tembec’s boiler operators is now operation,” Dottori says. “We started replacing in making this project a success,” says simplified. “We now run two boilers – a high- our refractory-lined digester vessels with du- Marc Barrette, Mill Manager of the Specialty pressure bark boiler which had a small 8 MW plex stainless steel, which will give us additional Cellulose mill. Barrette was Project Owner for turbine, and the new ANDRITZ boiler,” says capacity in each of the 11 units.” the boiler project, responsible for commission- Trevor Turner, Head Operator. “With this proj- ing and start-up. “Our operators and the com- ect, we shut down the small turbine since it Much-needed project missioning team worked long hours on many was only back-pressure and now have all the Trevor Turner and Dan Guénette, now both consecutive days during the training and com- steam flowing through one high-efficiency tur- Head Operators, were appointed Operating missioning phases.” bine with a condensing unit.” Commissioning Coordinators and were in- volved with the project from the very begin- Turn the page Fouling is considerably reduced with the ning. The fact that the ANDRITZ boiler re- “The project is over; the boiler is built,” Dottori ANDRITZ boiler. According to Michel Monet, places three units creates a new mindset, says. “Now it is Operations' job to turn the Steam Plant Superintendent, the arrange- according to Guénette. “When this boiler is page and look forward to the next 30 years. ment of the heat transfer surfaces in the down, the mill is down,” he says. “So, we are That is how we are working with ANDRITZ – SulfitePower boiler allows his operators to training every operator to be at a high level to shifting from project mode to operating mode: optimize temperatures in specific zones to match our best people.” maintaining, optimizing, and then looking at reduce fouling and potential corrosion. “This, future opportunities.” coupled with the horizontal configuration of “Any large project requires a little time for the the economizer and superheater, will hope- operators to get accustomed to it,” Turner Dottori says the team made a lot of very good fully help us extend the time between major says. “But our operators have been up to decisions in terms of equipment selection. outages,” he says. the challenge. We are making adjustments “You can see that in the way that the mill is day-to-day to further improve the boiler’s operating today,” he says. “Our digesters and About 78.5 t of wet liquor at 50% dry solids performance. Now that the operators are the board machine are performing better be- can be burned each hour. This equates to learning the boiler, we are giving them more cause of the solid and stable steam supply we 942 tds/d producing 222 t/h of high-pressure flexibility.” are delivering to them. The boiler is big and steam. Ammonium bisulfite is recovered in the robust, with spare capacity at the moment. It flue gas cleaning plant. Currently, due to limita- Turner and Guénette agree that the boiler is burns difficult liquors quite effectively. We’re still tions in the fiberline and evaporation plant, the a much-needed addition. “The SO2 emissions optimizing, but overall we are happy.” red liquor is responsible for about 80% of the from any sulfite mill must be tightly controlled,” capacity of the SulfitePower boiler. Natural gas they say. “This boiler does that superbly. This is Cousineau agrees. “I would definitely do anoth- is now the supplemental fuel to achieve the a great thing for the environment and the local er project with ANDRITZ,” he says. “That’s the steam capacity needed, but the boiler is de- community. The boiler runs well and stabilizes bottom line.” signed to burn red liquor without supplemental quickly. We can adjust liquor flows and air ra- fuel and sized to allow for upgrades in pulping tios based on pulp mill needs, with most of the CONTACT Wolfgang Oberleitner capacity. operation in automatic mode.” [email protected] 25 EVERYTHING HERE IS BIG
Interview with Júlio César Rodrigues da Cunha, Fibria’s Director of Engineering and Projects and Joel Starepravo, ANDRITZ Project Director
The second pulp production line at Fibria’s Horizonte mill near Três Lagoas will have a capacity of 1.95 million tonnes per year of bleached eucalyptus pulp. That will bring total production at the site to 3.05 million tonnes per year, making Horizonte one of the largest pulping sites in the world. Total investment in the second line is BRL 7.5 billion (USD 2.3 billion). ANDRITZ is supplying all the process areas (woodyard, fiberline, pulp drying, chemical recovery, and power island) on an EPC basis. We spoke with the Project Directors from both Fibria and ANDRITZ to get a status report on how the project is progressing.
Even though this is the largest equipment in the world, I don’t have any doubts.
Júlio César Rodrigues da Cunha 26 NO. 34 / 2-2016
Júlio César Rodrigues da Cunha, Director of Engineering and Projects for “My dream is that Fibria we leave a positive legacy for Fibria and the country of Brazil.”
Joel Starepravo
Background for the project for commercial negotiations, they asked if if we couldn’t come up with a creative da Cunha: “We have been planning the we would be interested in some new ideas solution. Our technical team designed a second line here at Horizonte for years and to get design capacity up to 1.95 million bigger washer, on paper. But we didn’t have quite intensely since 2013. Our original t/a. Of course, they had our complete the manufacturing machinery to make that calculations put the maximum line size at attention. We talked through the morning size of a drum. Our people in Finland set 1.5 million t/a. We kept wondering, though, about what changes would be necessary the wheels in motion to add a section to the if there was something we could do to and our technical people had intense workshop, acquire the larger machinery, make the economics more attractive. With discussions with their technical team. By and be able to manufacture these larger some changes here, and an addition there, the end of the day, we had a solution.” drums. When we presented our solution, we arrived at a new conceptual design for custom-tailored to Fibria, we had a deal.” a 1.75 million t/a mill.” Starepravo: “In the fiberline, Fibria wanted four of the DD Washers to be as big as No doubts ANDRITZ approached us possible. The size of our largest existing da Cunha: “Even though this equipment with some new thinking drums would limit production to 1.75 million is the largest in the world, I don’t have da Cunha: “When it came ANDRITZ’s turn t/a. We knew that would be a deal-breaker any doubts. Of course, with any project NO. 34 / 2-2016 Interview Rodrigues da Cunha 27
there are risks. But I can tell you these infrastructure in place before the civil Not just the people building the mill inside are all calculated risks. The concepts and contractors came on-site. Even during our the fence, but also all the related activities designs are proven. We trust ANDRITZ. rainy season, the contractors could work from the plantation nursery to shipping We have worked together for a long effectively.” and logistics. This is truly a big team time. The real risk for us is schedule, as effort.” we are on a fast-track delivery for all the da Cunha: “I have been doing project work equipment. for 30 years. This is the first project I have Lessons learned been involved with where we will start the Starepravo: “The lessons learned from Starepravo: “Fibria signed the contract mechanical erection with all the flooring, previous large projects is that the first for purchase in July 2015. Our schedule drainage systems, etc., in place.” 100 days are critical to the success of a is to start-up the line in the fourth quarter project. If you don’t get started on the of 2017. As of now, we are on target, in A complete team right things at the right speed, you are fact just a little ahead, with the civil work da Cunha: “One thing we have chosen forever playing catch-up. We are fortunate almost complete. Fibria did a great job to do differently here is to co-locate that the timing of the Klabin Puma Project getting all the roads, sewers, and other everyone on our team to the same offices. allowed us to move our teams from one 28 NO. 34 / 2-2016
large project directly to another. This keeps the continuity. We are focused on ABOUT JÚLIO CÉSAR ABOUT JOEL STAREPRAVO making sure that the engineering is solid, RODRIGUES DA CUNHA that our subcontractors have the guidance Early years Early years they need to work effectively, and that the Born in Araguari, Minas Gerais State; Born in Curitiba; 46 years old manufacturing quality and schedule can be 53 years old ensured.” Education Education BSc Information Systems
Improved tools and methods Electronic Engineering degree MBA International Project Post Graduate in Pulp & Paper Management Starepravo: “We recently completed an Process Fabrication Post-MBA in Negotiation internal development program involving MBA in Business Management PMP Certificate worldwide project teams to improve capa- bilities. During that program, we developed Work life Work life better systems and tools to help us manage First job as process control First job as process control su- engineer pervisor at Rigesa (WestRock) risk and identify potential problems before Process engineer for paper mill paper mill they become real issues. We also are using and consulting engineers Extensive experience in commis- new measurements to understand our Process and Project Engineering sioning and start-ups (Veracel, true productivity – not just the traditional management at VCP CMPC, Suzano, Fibria, etc.) percent-complete scale. We address areas Project Director at Bahia Pulp Engineering Manager (EIA) where we are slipping behind and take Currently Project and Currently Project Director for corrective actions with our customer before Engineering Director at Fibria Horizonte 2 there is a chance to seriously impact our Private life Private life schedule, quality, or safety. Married Married Hobbies include travel and having Hobbies include biking, running, Leaving a legacy fun with family/friends and movies Starepravo: “This is obviously an important Most important lesson Most important lesson project for ANDRITZ, our largest. My People are the key to project Commitment and communication dream for this project is that we not only success are essential to the success of a deliver what we have sold and make the Open and shared management, project, encompassing all levels customer happy, but also that we leave a combined with committed and in a company. The organization positive legacy for Fibria and the country well-prepared professionals in the as a whole should be aware of of Brazil.” right positions, will overcome any the project and be encouraged to challenge. participate. NO. 34 / 2-2016 Tech Talk 29
Tech ENERGY- Talk EFFICIENT FIBER TREATMENT with Durabond refi ner plates
The cost of fi ber and energy represent about 60% of a paper mill’s manufacturing cost. Optimizing refi ning action with the proper refi ner plate technology can, therefore, have a signifi cant impact on the bottom line. This TechTalk discusses the development of low-cost, energy-effi cient fi ber treatment in the refi ning process.
Energy is a large component of cost for the of Net Refi ning Energy. This is calculated as energy, however, can still be optimized by paper industry, accounting for about 16% the gross refi ning energy reduced by the so- utilizing its exponential dependency on rota- of total production cost. When you add the called no-load energy. No-load is the power tional speed and rotor diameter (measured cost of fi ber (approx. 44%), these two fac- consumed when the refi ner is in “idle” mode at stable and continuous fl ow with water at tors constitute about 60% of a paper mill’s (i.e., stock fl owing through the refi ner, motor operational refi ning gaps) based on calcula- manufacturing costs. Factoring in the mac- at normal operating RPM, and refi ner plates tions in Figure 2.
ro infl uences of CO2 reduction schemes, farthest apart so that there is no impact on renewable energy policies, and energy ef- fi ber morphology). fi ciency policies, the ability to save energy No-load power = k x Diameter4.25 x RPM3 with a very low investment cost is an impor- At the proper “nature of refi ning,” this Net tant factor in a mill’s profi tability. Refi ning Energy demand can be determined Figure 2. No-load equation. by the requirements of the paper machine No-load savings relative to the fi ber type used. Once fi ber In this equation, it is possible to reduce Effective fi ber treatment in a refi ner requires treatment is optimized, this portion of en- no-load power by reducing the active plate what we generally term as the expenditure ergy consumption is fi xed. The no-load diameter or reducing the rotational speed (RPM) of the refi ner. A versatile, but capital- intensive option to optimize no-load power Figure 1. is to reduce the refi ner’s speed by installing Paper machine Refi ner energy use Best practice energy values a frequency converter. An option to optimize Product energy use [kWh/ADt] [kWh/ADt] ( fi n a l a n d gross power consumption, which is also an primary) for Final Primary* Final Primary* standalone option that requires no capital investment, paper mills in is to reduce the active plate diameter of the Glassine 900 2.727 400 1.212 the world. Uncoated fi ne 640 1.939 144 436 refi ner plate (Figure 3). Packaging 535 1.621 112 339 Ultimately, the amount of energy savings Newsprint 570 1.727 68 206 that can be achieved through active plate Tissue 1.000 3.030 44 133 size reduction is limited by the accompany- ing drop in available edge length (change in ADt = Air-dried metric tonne * Primary energy assumes electricity generation, transmission, and distribution losses of 67% the “nature of refi ning” towards higher in- 30 NO. 34 / 2-2016
tensity) and hydraulic capacity of the plates Figure 3. Energy (lower pressure at same flow). Active Reduced reduction Estimated power savings Annual power savings plate plate potential: [kWh] [kWh/a] final and Durabond development diameter diameter primary. Pursuing minimal Total Cost of Ownership Inch Inch Final Primary* Final Primary* (TCO) for its customers, ANDRITZ began an 46 43 43 130 339.012 1.027.20 6 intensive development program resulting in 42 39 50 152 394.200 1.194.426 the Durabond plate family. 38 35 35 106 275.940 836.098
For any new refiner plate manufacturing 34 31 42 127 331.128 1.003.318 method to be worthy of consideration, it 30 27 27 82 212.868 644.990 must exceed the capabilities of current pro- 26 23 33 100 260.172 788.321 duction methods and lead to improved per- 20 17 32 97 252.288 764.433 formance. The Durabond family (Durabond and Durabond Light) accomplishes this. The Power savings calculations are based on 90% availability * Primary energy assumes electricity generation, transmission, and distribution losses of 67% bars on Durabond plate have zero side angles (no draught) and smooth groove surfaces to achieve the best hydraulic performance. A high ratio of bar height to width (thin tall bars) proprietary Fiber Floc Analysis (Figure 4). cision. Precision lasers are used to cut bars increases service life, while optimized bar and This analysis guides a specialist in tailor- from work-hardened stainless steel. These groove widths allow maximum available edge ing the bar and groove dimensions of the bars are then inserted into the laser-cut slots length. This makes it possible to operate op- Durabond plate to a mill’s specific pulp, in the base plate (Figure 5). timally with a reduced active plate diameter. which in turn allows minimizing the plate New bar materials allow for high wear as well diameter at optimum fiber quality. By ad- Laser technology represents the highest as breakage resistance. These elements are all dressing fiber treatment and energy sav- standard in accuracy and repeatability. This necessary preconditions for optimizing TCO. ings at the same time, the Durabond solu- is combined with low-temperature bonding tion is truly a holistic approach to lowering techniques to ensure that distortions from Durabond plates outperform current manu- TCO. warp and twist are eliminated. Proprietary facturing methods by providing: bonding agents are used, which are safe Durabond manufacturing and durable in elevated temperature ap- Tightly controlled and highly consistent The innovative concept behind Durabond plications such as TMP post refining. The bar heights manufacturing is to disassociate the materi- modular construction method ensures the High height-to-width bar ratios for long als for the refining bars from the materials for highest strength and sturdiness. life the segment base plate. This allows the use Bar materials that achieve the best of new materials (i.e., work-hardened steel) Regular and light versions combination of toughness and wear and new manufacturing methods to create a For disc refiners from 12-26ʺ rotor size, resistance refiner plate with minimal weight, maximum Durabond refiner plate segments are produced Smooth groove surfaces toughness, and the highest repeatable pre- in their regular shape (Figure 6), because seg- Zero bar side angle (“draught angle”) Superior balance due to minimal differ- Figure 4. Fiber floc analysis. ences in segment weights Safe and easy installation of low-weight segments Zero pulp/dirt accumulation due to closed back design
A holistic approach Over the last years, ANDRITZ has com- plemented its proven Magnus Refining Simulator, an aid in the development and fine-tuning of plate designs, by “dialing-in” to a mill’s specific requirements through a NO. 34 / 2-2016 Tech Talk 31
Figure 5. pabilities, Durabond plates can be installed Durabond laser-cut on every single- or double-disc refiner in bars. the market.
CONCLUSION Focusing solely on energy effi- ciency in refi ner plate applications limits the likelihood of sustainable success. Pursuing the best fi ber treatment and energy efficiency ments for refi ners of this size are comparatively Best applications for Durabond combined should, therefore, be the small and lightweight. Segments for refi ners Since Durabond refiner plates feature spe- goal. This involves detailed refi ning with rotor sizes larger than 26ʺ are usually cifically tailored bar geometries for maxi- system audits by qualifi ed product more demanding and diffi cult to install be- mum fiber quality development at minimum specialist, analyses, and Magnus cause of their size and weight. plate size, they work best in applications simulations. The result will be a where fiber quality development is critical customer-specific optimum bar For these larger sizes, ANDRITZ devel- (e.g., tissue, printing/writing grades, TMP and groove confi guration at mini- oped a multi-segment design concept – post refining, high-test packaging grades, mum plate diameters. In this way, Durabond Light – with the maximum weight etc.). The energy-saving characteristics of Durabond will sustainably improve of any segment at 20 lb (Figure 7). the plate design, however, are applicable the bottom line of paper mills. in virtually all refining applications. With the Durabond Light segments are mounted on a exception of sauerkraut, hot stock, and reusable base plate, which is delivered with deshive refining, all raw materials and quali- the fi rst installation (Figure 8). This makes ties can be processed and optimized with CONTACT Markus Müller the changing of refi ner plates safe and easy. Durabond. With the flexible mounting ca- [email protected]
Figure 6. Regular Durabond segment. Figure 8. Durabond Light mounting method.
Figure 7. Durabond Light segment. 32 NO. 34 / 2-2016
Iggesund Paperboard’s mill in Workington, UK will soon celebrate the 50th anniversary of its first production run. But, this is a company that focuses mainly on the future. Following the latest in a line of investments, it recently restarted its board machine after ANDRITZ rebuilt the press section – increasing capacity 10% and reducing energy consumption by almost 10%.
Europe’s folding boxboard market is in tran- years. On BM2 itself, the mill previously had Scheiflinger, Vice President Paper and Board, sition with new machines starting up. “The upgraded the wire section. At another time, believes this analysis convinced the Iggesund supply/demand situation has changed since ANDRITZ installed a new hood for the Yankee team that the press section needed to be up- we decided to rebuild the press section of cylinder. Iggesund also invested in a new bio- graded before anything else, because there BM2,” admits Ulf Löfgren, Mill Manager fuel boiler (an ANDRITZ unit) in 2011, switch- would be little point in increasing capacity at Workington. “But the investment is still ing from natural gas to biomass energy. Even elsewhere if the press section remained a quite valid. We wanted increased volume after these investments, the work continues. bottleneck. and consistent quality with reduced energy As Löfgren says, “We are in a good place, but consumption. Our strategy is to focus on the you must always improve. It must be good. It And removing bottlenecks to increase pro- premium segment and we have a very good must be brilliant!” duction is a genuine priority at Workington. product with good quality.” The infrastructure at the mill is set up for about Tonnes of quality 250,000 t/a of packaging board production. Sweden's Holmen Group, parent company As part of the pre-project analysis, ANDRITZ Production of cartonboard reached its peak of Iggesund Paperboard, has been invest- sent a team of experts to assess different in 2008, when Workington was operating ing progressively in Workington’s future for options on the machine. ANDRITZ’s Roland two board machines. The mill’s on-site pro-
It must be good. IT MUST BE BRILLIANT! NO. 34 / 2-2016 Iggesund Paperboard 33
duction of mechanical pulp for their board’s As the UK’s only producer of paperboard Talking shop inner layers is sized to support this level of using virgin fiber, Workington does not In planning the project, ANDRITZ and production. The future target of increasing compete with other UK mills, but rather Iggesund Workington spent time discuss- BM2’s capacity will bring the mill’s pulp and with producers of solid bleached board and ing the best configuration for the press board production back into balance. folding boxboard around the world. “In the section: two shoe presses vs. the com- last decade, our strategy has been to move bination of a long-nip press (LNP) with “It is extremely important to get tonnes onto up the quality chain and focus on premium a shoe press. According to Scheiflinger, the market,” Löfgren says. “That is of great segments,” Löfgren says. “In these premi- “two shoe presses would give more uni- value to us.” um segments, product quality needs to be form dewatering and better bulk, plus the same on Monday morning as it is on higher throughput. On the other hand, the Indeed, Workington could have gained ad- Saturday night.” combination of an LNP with a shoe press ditional capacity by upgrading other parts would provide both stiffness and dryness. of BM2 before the press section. But main- Workington produces the Incada brand of In either case, these would be followed by taining, and even improving, product qual- packaging board, which is available only a smoothing press.” ity was also key. Löfgren explains it in this in the GC1 and GC2 qualities. Incada was way: “The press section is a critical part re-specified and re-launched in 2013, and Gary Pickering, Head of Workington’s Project of any machine, impacting efficiency, eco- is now among the most recognized fold- Department and Project Manager for this re- nomics, and quality. Not only was the press ing boxboard brands in Europe, along with build, says, “We had been looking at press section on BM2 a bottleneck, upgrading it Iggesund’s Invercote brand. Incada is sold for section options for two years. At first, we also offered the best potential for a boost high-quality packaging of cosmetics, phar- were only considering the pick-up roll, but in product quality all the way down the maceuticals, confectionery, and premium or the scope expanded and every time it did, machine.” luxury items. there was a justification for it. In the end, we
IT MUST BE BRILLIANT! 34 NO. 34 / 2-2016
replaced everything and opted for the com- Pressing matters eral technical advantages to the installation bination LNP and shoe press.” ANDRITZ installed a complete new press sec- at Workington. “First, the shoe press is a tion including a long-nip jumbo press with large- very low-maintenance design and gives the Scheiflinger believes that the work his team diameter rolls, an energy-effi cient PrimePress X mill fl exibility in choosing the belt supplier. did at the front-end showed Workington shoe press in the second nip, and a smoothing Second, the hole design in the Uhle boxes people that ANDRITZ really understood the press. The delivery also included ANDRITZ’s was a big plus and the simplifi ed vacuum machine. Löfgren concurs. “Our decision state-of-the-art PrimeFeeder vacuum system system for the wire and press section allows to award the order to ANDRITZ was based for ropeless tail threading from the press sec- the existing vacuum pumps to be controlled on the work they did in the pre-decision tion to the dryer section. Erection services, individually. Finally, the automation includes phase,” he says. “They worked closely with commissioning, start-up, and optimization our state-of-the-art PrimeControl system us and showed us that they wanted the were all part of the package. which features ANDRITZ-written software project. We felt we would be able to work on PCS7 hardware from Siemens.” with them in a good atmosphere of coop- “In addition to the press hardware,” says eration and partnership. We have a lot of Barbara Freyler, ANDRITZ Director of Workington working confidence, trust, and belief in ANDRITZ. Order Execution, “we supplied new drives The plans looked good on paper. How did We were in the same boat together. It has for the wire and press section, the motor everything go in reality? been a successful project.” control center, multi-motor integration with BM2’s existing drive system, an ANDRITZ Löfgren says, “The project went very well. Scheiflinger sums it up: “We tried to be a FibreSolve broke repulper under the ma- We met all of our major milestones. A lot very proactive partner, not just a supplier. chine, all the power and data cabling, fi eld of praise and credit goes to the ANDRITZ We didn’t just want to deliver hardware, but instrumentation, and electrifi cation.” team – they were excellent. The machine we wanted to improve the performance of achieved the target quality and produced the machine.” According to Scheifl inger, there are sev- saleable board quickly after start-up.”
The project went very well. We met all of our major milestones. A lot of praise and credit goes to the ANDRITZ team.”
Ulf Löfgren Mill Manager; Iggesund Paperboard, Workington mill
The ANDRITZ PrimePress X shoe press is a very low-maintenance design that gives the Iggesund Workington mill the required bulk and dryness for its premium board products. NO. 34 / 2-2016 Iggesund Paperboard 35
“We have gained speed on all grades, in- We have gained cluding the higher grammages where we did speed on all grades, not think we would,” Pickering says. BM2 including the higher gram- was press limited to about 450 m/min. It is now mechanically designed to run up to mages where we did not 800 m/min, although speeding up the ma- think we would.” chine largely depends on future upgrades.
Commenting on the new vacuum system, Gary Pickering Head of Project Department; Iggesund Pickering says, “We were worried that we Paperboard, Workington mill might not have enough vacuum capacity. With the new design, we can run with one spare pump. It is working even better than Pickering adds: “There was a sheet on the ready evident, while others will only be seen we expected.” reel in well under a half day. It was a big in the future. “Our customers want lighter achievement for all of us because it was a weights,” Löfgren says, “so we are push- The last word goes to Mill Manager Löfgren: tough timescale.” ing to get the desired bulk with lower gram- “ANDRITZ has done a great job. If anything, mage. We believe we now have the founda- they have strengthened their position.” According to Freyler, “Our teams worked as tion to do this." one and never lost sight of the main goal. We learned from each other and about ourselves.” Scheiflinger adds, “Board stiffness has been increased at all grammages, while CONTACT Roland Scheifl inger Many of the results of the upgrade are al- the bulk remains similar. That was the goal.” roland.scheifl [email protected]
ANDRITZ installed a new press section on Iggesund’s BM2, including a long-nip jumbo press with (L to R): Ulf Löfgren, Mill Manager, Iggesund Workington Mill; large-diameter rolls, an energy-effi cient PrimePress X shoe press in the second nip, and a smoothing Barbara Freyler, ANDRITZ Director of Order Execution; Roland press. The delivery also included ANDRITZ’s state-of-the-art PrimeFeeder vacuum system for ropeless Scheifl inger, ANDRITZ Vice President Paper and Board, and Gary tail threading from the press section to dryer section. Pickering, Head of Workington’s Project Department. Gerhard Schiefer Head of ANDRITZ AUTOMATION
SMART Simulation as a part of the design fl ow.
In the context of Industry 4.0, “simulation” is one of the buzzwords. It is typically used in the context of process industries, for example the pulp & paper industry, to describe systems that model the process to virtually train operators before the actual plant is started up. But, are there new uses and new opportunities for simulation technologies?
Simulation technology has been utilized control loops in a plant’s distributed control SMART Simulation: quality enhance- in certain industries for some time. We system and then act as an operator training ment and risk reduction are all familiar with fl ight simulators, for tool. The results of using simulation are well Another new development is the use of example, which are used to train military documented – faster start-ups, quicker re- simulation technology as a design tool. For and airline pilots. The simulators can be sponse to process disturbances, and faster example, ANDRITZ is implementing SMART quite realistic – presenting various sce- ramp-ups to full production. Simulation upstream in the design process narios to trainees in a safe, virtual en- to dynamically and digitally verify the design. vironment so they can learn to master In addition to this familiar use of simulation For process design, we use the SIM-ALE critical situations. technology, what are the latest develop- platform. For machinery design, we use the ments? One development is the extension IN-LINE platform. In a similar way, ANDRITZ’s IDEAS dy- of the IDEAS Simulator so that it can be de- namic simulator is a cutting-edge tool ployed as a certifi ed operator training sys- SIM-ALE for process design in pulp and paper mills. It produces an tem. This has been utilized at the Zellstoff Within ANDRITZ, we have a common exact virtual model of the customer’s Pöls mill in Austria to carry out the recur- computer-assisted engineering system for process and the operator interface. rent training required by the mill’s insurance process, functional, automation, and in- Typically, IDEAS is employed to verify company to certify safe operation. strument design that we call the ANDRITZ NO. 34 / 2-2016 ANDRITZ AUTOMATION 37
Uniform Tool. In order to simulate the ufacturing. This eliminates major design interface. A sensor or machine error functional specifi cations being designed fl aws, improves the overall quality of the can be simulated to verify how the ma- in this engineering tool, we developed the machinery, and shortens the time for com- chinery stops the bale packing process Simulated ANDRITZ Logic Engine (SIM- missioning and start-up. The IN-LINE tool and alerts the operator. By opening the ALE) to simulate the functional behavior of runs on virtual machines simulating the op- alarm screen, detailed information about the process in combination with our IDEAS erator interface and the real machine. All of how to eliminate the fault can be shown. system that simulates the process itself. the machine’s inputs/outputs are included, Once this design is perfected and veri- This combination gives us the ability to verify as well as the actual operator interface, so fi ed, the design is locked and passed to the effectiveness of our design very early in that different operating scenarios (including manufacturing for commercial release. our workfl ow – reducing downstream errors failures) can be simulated and tested. and expensive rework. For example, when we apply our IN-LINE Watch our video IN-LINE for machinery design design verifi cation tool to our bale handling With our IN-LINE simulation tool, the func- machine (dried pulp bales), we can simu- tional behavior of a machine is tested late the actual bale transfer. All sensors and against the application design prior to man- actuators are shown in the simulated user NO. 34 / 2-2016
Environmental concern is deeply embedded within Sweden’s DNA. ANDRITZ recently added to this environmental commitment by supplying a biomass combined heat-and-power (CHP) plant to keep residents of the town of Mjölby warm in the winter – using renewable fuels from local forests. NO. 34 / 2-2016 Mjölby-Svartådalen Energi 39
With a workforce of just 65, Mjölby- Kjellberg was talking to SPECTRUM in A decision had to be made Svartådalen Energi (M-SE) is a lean company M-SE’s offices overlooking the brand new It was 2010 when it became very clear that that supplies district heating and electricity to plant supplied by ANDRITZ. Inside the boiler the existing boilers were at maximum capac- the people in Östergötland County, Sweden. house is a 35 MW EcoFluid (bubbling fluid- ity. “With the units being over 30 years old, In addition, the company is impressively ized bed) boiler along with all the attendant it was time to look at something new,” says green, as exemplified by its slogan “Lokalt infrastructure and automation technology. Kjellberg. “We have always been able to keep producerad energi från skog, vind och vat- up with local heating requirements thanks to ten” (“Locally produced energy from wood, In the beginning, district heating was supplied our pipeline link to a CHP plant in Linköping, wind, and water”). to the 26,000 residents of Mjölby by oil-fired 35 km away. But the Mjölby plant was clearly boilers. In the mid-1980’s, the first biomass- being put under more and more pressure.” Producing energy and heat from renew- fired boiler (12 MWth) was purchased. Small able sources is a carefully devised strategy. biomass-fired boilers were also purchased M-SE's management had already con- Christer Kjellberg, Head of Projects at M-SE, in the late 1990’s (9 MWth) and in 2008 ducted feasibility studies for a biomass says, “It is the company mission to produce (5.5 MWth). The investment in a new boiler CHP plant beginning in as much energy, electricity, and district heat- was driven not only by the age and relative 2008 with a pre-study. ing from renewables – hydro, wind, and wood efficiency of the existing boilers, but also by “We did a lot of work and – as we can. Last year, over 90% of our out- the desire to reduce dependence on fossil had many discussions,” put was locally generated from renewables. fuels and to lower the overall cost of produc- Kjellberg explains. “It was We are setting records in this region, and ing district heating. “Our existing boilers were in 2012 when serious even in Sweden.” becoming less efficient, and we needed more discussions were taking capacity,” Kjellberg says. “More importantly, place and then the final by adding CHP capabilities, the income we decision came in June produce from power production can be used 2013.” to offset the district heating production cost.” M-SE issued a tender to six companies for a new NO. 34 / 2-2016
biomass power plant that would use wood Manager. “The rest was civil works carried chips, forest residues, and sawdust as fuel. out by a Swedish company. We delivered Design capacity was to be 35 MW for heat, the EcoFluid BFB boiler, fuel handling sys- and 10 MW of electricity. “We knew what tem, fl ue gas cleaning system, steam turbine we wanted from the start,” says Kjellberg. with auxiliaries, and the electrical systems.” “We provided a scaled-down sketch of how we wanted the new plant to look and made Renewable, sustainable fuel a 3D model of the building before we sent The fuel for the plant comes from within a out the tender.” 30 km radius and is predominantly in the form of waste from the forest, but also in- During the tender process, M-SE visited two cludes wood chips, bark, and sawdust. important ANDRITZ references in Sweden Occasionally logs are bought and a local (Söderhamn and Bollnäs). ANDRITZ was se- contractor produces chips from the logs in lected to supply almost the complete plant the CHP plant’s woodyard. except for the ground and civil work for the foundation, as well as an HV cubical after The fuel handling system supplied by the turbine. The contract was signed on ANDRITZ includes equipment to receive September 12, 2013. The ANDRITZ teams 400 m3/h of biomass, all screening, storage in Austria and Finland supplied the boiler up to 4,000 m3, and conveyor systems to and the external fuel systems, and ANDRITZ feed the boiler. AUTOMATION in Austria delivered the low voltage equipment and the ABB control From rock to clay system. “The actual construction of the plant was quite a challenge,” says Kjellberg. “The ing one. In some places we had to blast “Everything that is visible above the ground ground here ranges from hard rock to bot- out hard rock and in other places we had in the new plant came from ANDRITZ,” tomless clay, and there was a challenge very soft clay, so we had to insert numerous says Christian Lackinger, ANDRITZ Project building a new plant so close to the exist- piles down to 20 meters to support the civil construction."
All challenges were overcome with excellent By adding CHP capabilities, cooperation, according to Lackinger. We started cold commissioning in May 2015, the income we produce from with hot commissioning following three power can be used to offset the months later,” he says. “The plant was fully taken over by M-SE in July 2016 after good district heating cost.” collaboration with our start-up team.”
Christer Kjellberg “Our plant operates seven months of the Head of Projects Mjölby-Svartådalen Energi year, and ran at full load for the fi rst time last winter,” says Production Manager Anders Ejhed. “Start-up went well. It took us some time to tune and optimize the operations, mostly focused on getting the biomass fuel mix right.”
Ejhed explains there were things for his team to learn. “The bubbling fl uidized bed boiler was new technology for us,” he says. “ANDRITZ people have been here to sup- port us at all times. The downtime during the summer months was a perfect opportunity for us to iron out any problems with the fuel, adjust the boiler, and thoroughly train our team at the site.” NO. 34 / 2-2016 Mjölby-Svartådalen Energi 41
Piping system.
L to R: Anders Ejhed, Production Manager; Christian Lackinger, ANDRITZ Project Manager; and Christer Kjellberg, Head of Projects.
Mjölby’s biomass fuel comes from a 30 km radius.
Flexibility - a major feature of Mjölby most plants, if you reduce electrical output, after firing up in October for the winter. We One of the main features of the new Mjölby you also reduce district heating energy. The expect the plant to operate at around 90% plant is the flexibility to adjust the electrical Mjölby plant is a bit different. We direct part of efficiency, and we have plans to improve this output from the turbine according to where the steam to a heat exchanger that converts even further by installing a flue gas condens- the energy output of the boiler is needed this steam input directly to district heating en- er. We already have the infrastructure in place most, or is most economically viable. ergy. So, M-SE can produce down to about to install it. This will be our next investment, Lackinger explains, “The main target is to 2 MW of electricity and up to about 31 MW of which will take our efficiency to around 98%.” provide district heating, but M-SE installed district heating energy at the same time. This a turbine to also produce electricity. From allows them to adapt to heating requirements the total fuel value of the wood chips, it is from the community, fuel mixtures, and the possible to produce 23 MW for the district need for electrical energy.” heating network and 10.8 MW of electricity. If you put all the steam to the turbine, the So what’s next for the Mjölby plant? Kjellberg CONTACT Markus Slotte ratio of electricity-to-steam is about 1:2. In says, “We should be running at full capacity [email protected] 42 NO. 34 / 2-2016 Highlights RECENT ORDERS
COMPLETE LINES Stora Enso, Kemi, Finland Naberezhnye Chelny Paper Mill AND SYSTEMS Fiberline modernization including new DD Washer Naberezhnye Chelny, Russia Conversion from single-stage to two-stage oxygen PrimeCoat Size size press, PrimeReel Standard Carta Fabril, Anápolis, Brazil delignifi cation pope reeler, machine drives, and two pulpers PrimeLineST W22 tissue machine including steel Follow-up order Sappi North America, Skowhegan, Maine, USA Yankee and steam-heated hood High-capacity debarking line and woodyard equip- Fibria, Jacareí mill, São Paulo, Brazil World’s largest steel Yankee (22 ft diameter) for ment Duct Stripper technology for two evaporation plants tissue Includes extra-large (XXL) HHQ-Chipper and 1st in Brazil for lamella evaporation plant; 1st in world Bashundhara Paper Mills, Dhaka, Bangladesh ChipperEKG condition monitoring for tube-type evaporation plant PrimeLineCOMPACT VI tissue machine includ- Sappi Southern Africa ing stock preparation, machine approach, and EQUIPMENT/UPGRADES Sappi Saiccor Mill, Umkomaas, South Africa automation Partial rebuild of economizer section of a Dong Hai, Ben Tre, Vietnam Heinzel Group, Laakirchen, Austria Sulfi tePower boiler 3 complete stock preparation lines and paper Conversion of SC paper machine to lightweight machine approach system containerboard (including new fi lm press and BMC Moerdijk, Moerdijk, Netherlands Repeat order (PM1 completed last year) PrimeDry Steel cylinders), new OCC line, approach Pressure parts for a boiler retrofi t system rebuild, sludge system, and rejects handling JSC Volga, Balakhna, Nizhnyi Novgorod Region, This will be ANDRITZ’s widest GapFormer and two- Propower, Eisenhüttenstadt, Germany Russia layer headbox (8.5 m) Retrofit and overhaul bed material cooler for Complete Advanced Thermo-Mechanical Pulp ANDRITZ power boiler (ATMP) line Shandong Bohui Paper, Zibo, Shandong, China Upgrade of BCTMP line Helsingør Kraftvarmeværk, Helsingør, Denmark 3rd major rebuild project of competitor’s technology Biomass boiler island for CHP plant Scope from fuel silos to boiler outlet Metsä Tissue, Kreuzau, Germany FiberFlow Drum pulper for tissue UPM, Kymi, Finland Equipment for upgrades to fi berline, white liquor Cartulinas CMPC, Planta Maule, Chile plant, and evaporation plant Bleaching stage upgrade
Suzano Papel e Celulose, Mucuri, Bahia, Brazil Caima Indústria de Celulose, S.A. Constância - Sul Fiberline upgrade; evaporation plant retrofi t Fabrica Constancia, Portugal Cutter/baling line rebuild
The steam drum for the largest recovery boiler in the Americas is shown being lifted into position at Fibria's Horizonte 2 construction site. The drum weighs 200 t and the lift was 70 m high (See SPECTRUM article RECENT START-UPS page 25).
COMPLETE LINES St. Croix Tissue, Baileyville, Maine, USA EQUIPMENT/UPGRADES AND SYSTEMS PrimeLineTM W8 tissue machine 2nd machine (see SPECTRUM article page 6) Vinda Paper, Sanjiang, Xinhui, Jiangmen, China Iggesund Paperboard (Workington) FRITZ EGGER, Gagarin, Russia Stock preparation line Workington, Great Britain New evaporation line for MDF plant Board machine rebuild with new press section Nine Dragons Paper Turnkey delivery excl. civil work (see SPECTRUM Walsin Lihwa, China Dongguan, Guangdong, China article page 32) AhlCleaner plant Equipment for zero-effluent mixed acid pickling process (metals) Zellstoff- und Papierfabrik Rosenthal Sun Paper, Yanzhou, Shandong, China Zemap evaporator – first of its kind Blankenstein, Germany OCC processing line, rejects handling, stock Lime kiln upgrade with LimeFlash lime mud drying preparation, machine approach, pulper Smurfit Kappa, Piteå, Sweden technology Capacity upgrade for evaporation plant Guangdong Shaoneng Group Electricity Authority of Turkish Republic of Northern Shao Guan, Guangdong, China Cyprus, Girne, Northern Cyprus PrimeLineCOMPACT II tissue machine with steel Retrofi t project for two 60 MW oil-fi red power Yankee, stock preparation, automation, drives boilers: engineering, supply, installation, and com- Part of furnish will be mill’s bamboo pulp missioning of superheaters and economizers DID
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No matter who the original manufacturer was, ANDRITZ offers a range of wash press service designed to troubleshoot, remove bottlenecks, solve outlet consistency issues, improve pulp quality, reduce COD loading, replace worn parts, assist during shutdowns, and upgrade pulp feeds and press rolls.
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